Volkswagen Golf Variant / Jetta. Manual - part 533

148

1

Input Shaft

⇒ “1.1 Input Shaft, Disassembling and Assembling”, page 149

1.1

Input Shaft, Disassembling and Assem‐

bling

Special tools and workshop equipment required
♦ Press Plate - VW401-
♦ Press Plate - VW402-
♦ Press Piece - Rod - VW407-
♦ Press Piece - Multiple Use - VW412-
♦ Press Piece - 60mm - VW415A-
♦ Press Piece - Shift Rod/Alternator - VW422-
♦ Press Piece - Multiple Use Spacer Sleeve - VW472/2-
♦ Press Piece - 42mm - VW516-
♦ Press Piece - Multiple Use - 30-23-
♦ Press Piece - Press Tube - 30-100-
♦ Press Piece - T10080-
♦ Press Piece - T10081-
♦ Circlip Pliers - VW161A-
♦ Press Piece - Trailing arm - 2010-
♦ Press Piece - Block - T10083-
♦ Press Piece - Block - Washer - T10083/1-
♦ Bearing Installer - Bearing Press Plate - T10084A-
♦ Puller - Kukko Internal - 28-37mm - 21/5-
♦ Puller - Kukko Counterstay - 22/1-
♦ Inductive Heater - VAS6414-
♦ -Feeler Gauge-

Note

♦

When install new drive gears. Refer to the technical data. Refer to

⇒ “1.2 Codes, Transmission Allocation and Capacities”, page 2

 and the Parts Catalog.

♦

Insert all bearings, selector gears and synchronizer rings on input shaft with transmission fluid.

♦

Do not exchange synchronizer rings, always allocate to original selector gear when reusing.

♦

Wearing safety gloves, warm the needle bearing sleeve, the gear wheels and the synchronizer hubs to

approximately 100 °C (212 °F) using an Inductive Heater - VAS6414- before installing them.

1. Input Shaft    

149

❑ Replace after removing
❑ Selecting thickness. Re‐

fer to 

⇒ page 125

 .

2 - Locking Collar with 5th Gear

Synchronizer Hub

❑ Removing and instal‐

ling. Refer to

⇒ “6.6 Disassembly and

Assembly Sequence”,

page 117

 .

❑ Disassembling. Refer to

⇒ Fig. ““Locking Collar

and 5th Gear Synchron‐

izer Hub, Disassem‐

bling and Assembling”“ ,

page 157

 .

❑ Assembling 5th gear

locking collar/synchron‐

izer hub. Refer to

⇒ Fig. ““5th Gear Lock‐

ing Collar/Synchronizer

Hub Assembly”“ ,

page 157

❑ Installation position. Re‐

fer to

⇒ Fig. ““Locking Collar

and 5th Gear Synchron‐

izer Hub, Disassem‐

bling and Assembling”“ ,

page 157

 .

3 - 5th Gear Synchronizer Ring

❑ Checking for wear. Re‐

fer to

⇒ Fig. ““Checking Syn‐

chronizer Ring for

Wear”“ , page 154

4 - 5th Gear Wheel
5 - Needle Bearing

❑ For 5th gear
❑ Replace together with -item 6- 

⇒ Item 6 (page 150)

6 - Sleeve

❑ For the 5th gear needle bearing
❑ replace together with -item 5- 

⇒ Item 5 (page 150)

❑ Remove with bearing mount/grooved ball bearing. Refer to

⇒ Fig. ““Remove the Bearing Mount and Grooved Ball Bearing”“ , page 152

❑ Installing. Refer to 

⇒ Fig. ““Install the 5th Gear Needle Bearing Sleeve -A-.”“ , page 156

7 - Transmission Housing
8 - Bearing Mount with Grooved Ball Bearing

❑ Only replace grooved ball bearing together with bearing mount
❑ if bearing mount is removed from transmission housing, it must always be replaced
❑ Removing. Refer to 

⇒ Fig. ““Remove the Bearing Mount and Grooved Ball Bearing”“ , page 152

❑ Installing. Refer to 

⇒ page 155

9 - Input Shaft
10 - Needle Bearing

❑ For 3rd gear

150

s

p

e

c

t

 t

o

 

th

e

 c

o

rr

e

c

t

n

e

s

s

 

o

f

in

fo

r

m

a

tio

n

 in

 th

is

 d

o

c

um

en

t.

C

o

py

rig

ht b

y

 

V

olk

sw

a

ge

n

 

A

G.

11 - 3rd Gear Wheel
12 - 3rd Gear Synchronizer Ring

❑ Checking for wear. Refer to 

⇒ Fig. ““Checking Synchronizer Ring for Wear”“ , page 154

13 - Locking Sleeve with Synchronizer Hub for 3rd and 4th Gears

❑ Removing with the 3rd gear wheel. Refer to

⇒ Fig. ““Removing the Bearing Inner Race for the Cylindrical Roller Bearing”“ , page 153

❑ Disassembling. Refer to

⇒ Fig. ““Disassembling and Assembling Locking collar and Synchronizer Hub for 3rd/4th Gears”“ , page

153

 .

❑ Installed position: locking collar/synchronizer hub. Refer to

⇒ Fig. ““Installed Position: Locking Collar/Synchronizer Hub for 3rd and 4th Gears”“ , page 153

❑ Assembling. Refer to

⇒ Fig. ““Assembling Locking Collar/Synchronizer Hub for 3rd and 4th Gears.”“ , page 153

❑ Installing. Refer to

⇒ Fig. ““Installing the Synchronizer Hub with Locking Collar for 3rd and 4th Gears”“ , page 154

14 - 4th Gear Synchronizer Ring

❑ Checking for wear. Refer to 

⇒ Fig. ““Checking Synchronizer Ring for Wear”“ , page 154

15 - 4th Gear Wheel
16 - Sleeve

❑ For the 4th gear needle bearing
❑ replace together with -item 17- 

⇒ Item 17 (page 151)

❑ Removing with the 3rd gear wheel. Refer to

⇒ Fig. ““Removing the Bearing Inner Race for the Cylindrical Roller Bearing”“ , page 153

❑ Installing. Refer to 

⇒ Fig. ““Install the 4th Gear Needle Bearing Sleeve -A-.”“ , page 154

17 - Needle Bearing

❑ For 4th gear
❑ replace together with -item 16- 

⇒ Item 16 (page 151)

18 - Thrust Washer
19 - Bearing inner race for the cylindrical roller bearing

❑ Removing. Refer to

⇒ Fig. ““Removing the Bearing Inner Race for the Cylindrical Roller Bearing”“ , page 153

❑ Installing. Refer to

⇒ Fig. ““Installing the Bearing Inner Race -A- for the Cylindrical Roller Bearing”“ , page 154

20 - Circlip

❑ Replacing
❑ Selecting thickness. Refer to 

⇒ Fig. ““Selecting the Locking Ring”“ , page 155

 .

21 - Cylindrical Roller Bearing

❑ With circlip
❑ Removing. Refer to 

⇒ Fig. ““Remove the Roller Bearing from the Clutch Housing”“ , page 152

❑ Installing. Refer to 

⇒ Fig. ““Pressing Cylindrical Roller Bearing into Clutch Housing.”“ , page 152

❑ Installed position: the circlip in bearing points to input shaft

22 - Clutch Housing
23 - Spring

❑ Installation position. Refer to

⇒ Fig. ““Assembling Locking Collar/Synchronizer Hub for 3rd and 4th Gears.”“ , page 153

 .

24 - Locking Collar for 3rd and 4th gear
25 - Synchronizer Hub for 3rd and 4th Gear
26 - Locking Pieces

❑ Quantity: 3

1. Input Shaft    

151